Interlocking landscape/building tiles

ABSTRACT

Landscaping/building tile systems comprising a plurality of individual tiles secured by a plurality of interlocking fastening strips. In one aspect, the tile systems comprise a plurality of tile sections, each of which includes a plurality of individual tiles, that can be secured together to form a single, unitary mat.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to an interlocking tile systemfor use in landscaping and architectural applications. In anotheraspect, the invention relates to a system comprising a plurality of tilesections secured together by a lattice structure of interlockablefastening strips.

2. Description of the Prior Art

Landscaping and architectural tiles are particularly popular buildingmaterials because of their attractiveness and durability. Architecturaltiles, particularly those used indoors as flooring and wall covering,are commonly made of ceramic, porcelain, or natural stone materialswhich makes the tiles particularly suitable for high-traffic, moistureprone areas. Conventionally, indoor architectural tiles are laid on asurface one at a time and must be secured together using grout.Occasionally, depending upon the wear and tear inflicted upon the tiles,the grout must be replaced. Also, the grout is susceptible to mold andmildew which can lead to discoloration thereof and damage the aestheticqualities of the tile system.

Landscaping tiles are useful in creating outdoor walkways, patios,borders and the like and most commonly are made from durable materialsthat are relatively weather resistant. Like the indoor architecturaltiles, landscaping tiles are conventionally laid one at a time and mustbe generally tightly packed so as to prevent weeds from growing uptherebetween. In some applications (particularly on uneven terrain) itmay be necessary to apply cement between the tiles in order to hold themin place relative to each other. Also, these conventional tile systems,which are relatively inflexible once set into place, are susceptible todamage caused by freezing and thawing cycles of the ground.

OBJECTS AND SUMMARY OF THE INVENTION

It is, therefore, an object of the present invention to provide aninterlocking tile system enabling relatively quick assembly of largesections of tiles into a single, unitary mat that does not require groutto hold the individual tiles in place.

It is a further object of the invention to provide a tile system that issufficiently flexible to follow the natural contours of a surface and toaccount for the swelling and contraction of the surface due totemperature changes.

It should be understood that the above-listed objects are onlyexemplary, and not all the objects listed above need be accomplished bythe invention described and claimed herein.

Accordingly, one aspect of the present invention concerns a tile systemcomprising: (a) a plurality of tile sections, each tile sectionincluding (i) a plurality of individual tiles cooperatively defining aplurality of transversely extending channels, and (ii) a mesh attachedto at least some of the tiles; and (b) a plurality of interlockablefastening strips received in the transversely extending channels andsecuring the tile sections to one another.

Another aspect of the present invention concerns a tile systemcomprising: (a) a plurality of individual tiles cooperatively defining aplurality of transversely extending channels; (b) a mesh attached to atleast some of the tiles; (c) a plurality of spacer blocks attached to atleast a portion of the mesh opposite the tiles; and (d) a plurality ofelongated, interlockable fastening strips received in the transverselyextending channels and securing the tiles to one another.

A further aspect of the present invention concerns a method of layingtile comprising the steps of: (a) placing first and second tile sectionsnext to one another, each of the tile sections including a plurality ofindividual tiles and a mesh attached to at least some of the individualtiles, the individual tiles cooperatively defining first transverselyextending channels within each of the tile sections, the first andsecond tile sections cooperatively defining a second transverselyextending channel therebetween; (b) placing a first interlockingfastening strip in at least a portion of the first channel of the firsttile section and in at least a portion of the first channel of thesecond tile section, the first fastening strip intersecting the secondchannel; and (c) placing a second interlocking fastening strip in thesecond channel between the first and second tile sections, the secondfastening strip interlocking with the first fastening strip.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

A preferred embodiment of the present invention is described in detailbelow with reference to the attached drawing figures, wherein:

FIG. 1 is an expanded view of an interlocking tile system with a latticestructure of interlocking strips that overlap between tile sections;

FIG. 2 is an exploded view of an interlocking tile system showing theindividual tiles, intermediate mesh, spacer blocks, and interlockingstrips;

FIG. 3 is a close-up cross-sectional view of an interlocking tile systemlaid upon a surface;

FIG. 4 depicts a tile anchoring system comprising a screw-type auger andwasher with a section of tile shown in phantom;

FIG. 5 is a top view of a wedge-shaped tile section;

FIG. 6 is a top view of a plurality of the tile sections shown in FIG. 6arranged to form a curved tile system;

FIG. 7 is a top view of a tile system having a pre-designed image formedby the assembly of a plurality of tile sections; and

FIG. 8 is a top view of another tile system having a pre-designed imagedformed therein.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring initially to FIG. 1, a tile system 10 is shown comprising aplurality of tile sections 12, each of which includes a plurality ofindividual tiles 14. Fastening strips 16, 18 are used to couple and locktile sections 12 together. The assembly of tile system 10 is describedin more detail below.

As shown in FIG. 2, tile section 12 includes a plurality of individualtiles 14 coupled together by a durable mesh section 20. Preferably, meshsection 20 is secured to the bottom surface 22 of tiles 14 by a firstadhesive layer 24 (see FIG. 3). Spacer blocks 26 are secured to mesh 20by a second adhesive layer 28. In alternate preferred embodiments, mesh20 may also be embedded within tiles 14 during fabrication thereof andspacer blocks 26 eliminated.

Tile section 12 comprises a plurality of transversely extending channels28, 30 defined by the edges of the plurality of individual tiles 14. Aplurality of fastening strips 16 are set in channels 28 which runsubstantially parallel to each other. Strips 16 comprise a plurality ofgrooves 32 which extend from the top edge 34 of the strip to some pointabove the bottom edge 36 of the strip. Preferably, grooves 32 extend tosome point proximate the mid-point between the top and bottom edges 34,36 of strip 16. Grooves 32 are positioned at the intersection ofchannels 28 and 30.

Strips 18 comprise a plurality of grooves 38 which extend from thebottom edge 40 of strip 18 to some point below the top edge 42 of thestrip. Preferably, grooves 38 extend to some point proximate themid-point between top and bottom edges 40,42 of strip 18. Strips 18 areplaced in channels 30 which also run substantially parallel to eachother, but intersect channels 28 is a substantially perpendicularmanner. It is not always necessary for channels 28, 30 to run parallelto each other, respectively, or intersect in a substantiallyperpendicular manner. As explained in the discussion of FIGS. 5 and 6below, these channels may be oblique relative to each other andintersect in an oblique manner. Grooves 38 are positioned at theintersection of channels 28 and 30 and mate with grooves 32 formed instrips 16. This interlocking action of strips 16 and 18 creates aunitary lattice structure that occupies at least a portion of the spacebetween tiles 14 and operates to fix tiles 14 in position.

Strips 16, 18 comprise a plurality of fastening tabs 44 attached to therespective bottom edges 36, 40 thereof. Tabs 44 are generallyhook-shaped and configured for insertion through mesh 20. The generallyhook-shaped structure of tabs 44 prevents the withdrawal of tabs 44 frommesh 20 and, consequently, the removal of strips 16, 18 from channels28, 30. Spacer blocks 26 operate to space mesh 20 from the surface 46(FIG. 3) upon which tile system 10 is applied and give channels 28, 30added depth so as to facilitate insertion of tabs 44 through mesh 20. Inthose embodiments that omit spacer blocks 26, i.e., where mesh 20 isembedded in tiles 14 during fabrication thereof, mesh 20 is placed atsome point between the top and bottom surfaces of tile 14, andpreferably at some point closer to the bottom surface than the topsurface of tile 14.

Strips 16, 18 are placed in channels 28, 30 so that only a portion ofstrip 16, 18 is located entirely within channels 28, 30 of any oneparticular tile section 12. It is preferable for at least a portion ofstrips 16, 18 be positioned in at least a portion of channels 28, 30 ofadjacent tile sections 12. Thus, adjacent tile sections 12 are securedtogether by strips 16, 18 and formed into unitary tile system 10. Anyportions of strips 16, 18 which extend beyond the outer boundaries oftile system 10 may be trimmed away as necessary.

Turning now to FIG. 3, a cross-sectional view of tile system 10 is shownafter being laid upon surface 46. Preferably, tile system 10 isinstalled on the ground and is useful for forming a tile patio, walkway,or simply a decorative landscaping feature; however, tile system 10 mayalso be used indoors. After a plurality of tile sections 12 are laidupon surface 46, fastening strip 16 is inserted into channel 28 andfastening tabs 48 are inserted through mesh 20. The tabs 48 illustratedin FIG. 3 depict an alternate embodiment than tabs 44 illustrated inFIGS. 1 and 2. Tabs 48 comprise a more arrow-like, or even pyramidal,shape as opposed to hook-shaped tabs 44. As shown, surface 46 provides arelatively level grade for tile system 10. In such an arrangement, it isnot necessary to permanently couple system 10 with surface 46. Theweight of system 10 is sufficient to keep it in relatively fixedposition with respect to surface 46.

Tile system 10 may also be used with uneven or sloping terrain. In suchapplications, the tile system 10 may be secured to the ground using ananchor 50 to prevent erosion of the underlying soil. In the embodimentillustrated in FIG. 4, one tile 14 and the corresponding spacer block 26are removed from tile system 10 by cutting through mesh 20. A retainingplate 52 is placed in the void left by tile 14. Plate 52 comprises anouter lip 54 which rests upon the top surfaces of tiles 14 adjacent tothe void. Plate 52 further includes a circumferential inwardly anddownwardly sloping sidewall 56 which terminates in a recessed surface58. Recessed surface 58 includes a central annular orifice formedtherein which enables anchor 50 to be inserted therethrough. The shaft62 of anchor 50 is helically flighted so that anchor 50 will bore intothe ground when rotated. Anchor 50 also contains a hex-head 60 so that awrench or socket may be used to rotate and drive anchor 50 into theground. Washer 64 provides a resting surface for hex-head 60 andprevents hex-head 60 from passing through the annular orifice ofrecessed surface 58. The anchoring system shown in FIG. 4 allows anchor50 to be located entirely below the grade of tiles 14 thereby reducingthe potential stumbling hazard presented by anchor 50.

Tiles 14 may be constructed of any natural or synthetic materialsuitable for use as tiling. Preferred tile materials include porcelain,concrete, stone, aggregate, brick, synthetic resin material (such asPVC, polypropylene, or polyethylene), metal, glass, wood, othercellulose-based materials, and combinations thereof. Preferably, thetile material is relatively fairly weather resistant, especially iftiles 14 are used in an outdoor application.

Likewise, mesh 20 is preferably formed from a durable, moistureresistant material. Preferably, the mesh material is also be relativelyflexible enabling anchoring tabs 44 to pass therethrough withoutbreaking. Preferred mesh materials include, natural and synthetic resinmaterials (such as rubber, polypropylene, polyethylene, nylon), naturaland synthetic fibrous materials, and metals such as stainless orgalvanized steel. The size of mesh 20 is selected in conjunction withthe size of the locking tabs 44 used therewith. Mesh 20 is large enoughto permit insertion of tabs 44 therethrough (taking into account someslight deformation of the mesh), but fine enough to prevent withdrawalof tabs 44 therefrom.

Fastening strips 16, 18 are also formed of a durable, moisture resistantmaterial. The strip material is preferably more rigid than the meshmaterial, but is still capable of some flexing, particularly forapplications in which channels 28, 30 are slightly curved. Examples ofthese types of applications are shown in FIGS. 5 and 6. Preferredfastening strip materials include both natural and synthetic resinmaterials such as those described above, and metals such as stainless orgalvanized steel. The aesthetic qualities presented by the fasteningstrip material is also an important quality because at least portion ofthe strips will be visible when strips 16, 18 are installed in channels28, 30. In this regard, the color of strips 16, 18 may be selected so asto contrast with the tiles, and may be of differing widths to furtheraccentuate various features of tile system 10.

FIGS. 5 and 6 depict wedge-shaped tile sections 66 that can be used tocreate curved portions in a tile system 68. Wedge-shaped sections 66 maybe manufactured as such, or, more preferably, formed by cutting arectangular tile section 12 with an appropriate tile cutting tool. Thewedge-shaped sections 66 may be used to create curving walkways orborders around objects such as trees and shrubs. It is important tonote, however, that the invention is not limited to merely rectangulartile sections 12 or wedge-shaped sections 66. Tile sections of virtuallyany shape may be cut and used with the present invention. Also, it iswithin the scope of the invention to use individual tiles that arenon-rectangularly shaped (i.e., triangular, hexagonal, octagonal,curvilinear, etc.). It is also possible for differing tile shapes to beused in the same tile section. For example, rectangular tiles may layadjacent triangular tiles, all of which being bound together by the samemesh 20. Of course, the shape of the tiles may affect the channelsformed between adjacent tiles, and thus alter the configuration of thelattice structure formed by fasting strips 16, 18.

Tiles 14 are secured together in such an manner so as to be flexibleenough to accommodate being placed on uneven surfaces and still allowwater to permeate therebetween and reach the underlying surface.However, tiles 14 and fastening strips 16, 18 are placed close enoughtogether so as to prevent grass or weeds from growing in between tiles14. Optionally, adhesive or mortar applied to the bottom surfaces ofspacer blocks 26 may be used to fixedly secure tile system 10 whensystem 10 is to be used in an architectural setting or as a high-trafficwalkway.

FIGS. 7 and 8 depict exemplary decorative designs which may be formedwith the present invention. As shown in FIG. 7, tile system is in theform of an United States flag having alternating rows of tiles 70, 72for the flag stripes and an field 74 having alternating tiles 14representing the stars. This tile system 10 may be packaged and sold asa complete unit enabling the purchaser to install this particular designin a preferred location. FIG. 8 is a fanciful design pattern formed by aplurality of identical tile sections 12 formed into a tile system 10.

The preferred forms of the invention described above are to be used asillustration only, and should not be used in a limiting sense tointerpret the scope of the present invention. Obvious modifications tothe exemplary embodiments, set forth above, could be readily made bythose skilled in the art without departing from the spirit of thepresent invention.

The inventor hereby states his intent to rely on the Doctrine ofEquivalents to determine and assess the reasonably fair scope of thepresent invention as it pertains to any apparatus not materiallydeparting from but outside the literal scope of the invention as setforth in the following claims.

1. A tile system comprising: (a) a plurality of tile sections, each tilesection including (i) a plurality of individual tiles cooperativelydefining a plurality of transversely extending channels, and (ii) a meshattached to at least some of said tiles; and (b) a plurality ofinterlockable fastening strips received in the transversely extendingchannels and securing said tile sections to one another.
 2. The tilesystem according to claim 1, said individual tiles presenting top andbottom surfaces, said mesh being attached to the bottom surfaces of theat least some of said tiles.
 3. The tile system according to claim 2;and (c) a plurality of spacer blocks attached to at least a portion ofsaid mesh and opposite said tiles.
 4. The tile system according to claim1, said fastening strips presenting top and bottom edges, said fasteningstrips comprising a plurality of fastening tabs attached to the bottomedges thereof.
 5. The tile system according to claim 4, said fasteningtabs being inserted through said mesh.
 6. The tile system according toclaim 1, said fastening strips having a plurality of grooves formedtherein.
 7. The tile system according to claim 6, at least one of saidtransversely extending channels intersecting at least one other of saidtransversely extending channels.
 8. The tile system according to claim7, at least one of the grooves of one of said fastening strips receivedin said at least one of said transversely extending channels receivingthe fastening strip in said at least one other of said transverselyextending channels.
 9. The tile system according to claim 1, at least afirst portion of one of said fastening strips received in a transverselyextending channel of one of said tile sections and at least a secondportion of said one fastening strip received in a transversely extendingchannel of another tile section.
 10. A tile system comprising: (a) aplurality of individual tiles cooperatively defining a plurality oftransversely extending channels; (b) a mesh attached to at least some ofsaid tiles; (c) a plurality of spacer blocks attached to at least aportion of said mesh opposite said tiles; and (d) a plurality ofelongated, interlockable fastening strips received in the transverselyextending channels and securing the tiles to one another.
 11. The tilesystem according to claim 10, said individual tiles presenting top andbottom surfaces, said mesh being attached to the bottom surfaces of theat least some of said tiles.
 12. The tile system according to claim 10,said fastening strips presenting top and bottom edges, said fasteningstrips comprising a plurality of fastening tabs attached to the bottomedges thereof.
 13. The tile system according to claim 12, said fasteningtabs being inserted through said mesh.
 14. The tile system according toclaim 10, said fastening strips having a plurality of grooves formedtherein.
 15. The tile system according to claim 14, at least one of saidtransversely extending channels intersecting at least one other of saidtransversely extending channels.
 16. The tile system according to claim15, at least one of the grooves of one of said fastening strips receivedin said at least one of said transversely extending channels receivingthe fastening strip in said at least one other of said transverselyextending channels.
 17. A method of laying tile, said method comprisingthe steps of: (a) placing first and second tile sections next to oneanother, each of said tile sections including a plurality of individualtiles and a mesh attached to at least some of the individual tiles, theindividual tiles cooperatively defining first transversely extendingchannels within each of the tile sections, the first and second tilesections cooperatively defining a second transversely extending channeltherebetween; (b) placing a first interlocking fastening strip in atleast a portion of the first channel of the first tile section and in atleast a portion of the first channel of the second tile section, thefirst fastening strip intersecting the second channel; and (c) placing asecond interlocking fastening strip in the second channel between thefirst and second tile sections, the second fastening strip interlockingwith the first fastening strip.
 18. The method according to claim 17,said first and second fastening strips comprising a plurality of groovesformed therein, step (c) further including the step of mating at leastone groove of the second fastening strip with at least one groove of thefirst fastening strip.
 19. The method according to claim 17, saidplurality of individual tiles cooperatively defining a thirdtransversely extending channel within each of the tile sections that issubstantially parallel to the first channels.
 20. The method accordingto claim 19; and (d) placing a third interlocking fastening strip in atleast a portion of the third channel of the first tile section and in atleast a portion of the third channel of the second tile section.
 21. Themethod according to claim 20, said third fastening strip interlockingwith said second fastening strip.
 22. The method according to claim 17;and (e) anchoring at least one of the first and second tile sections toa surface using a helically-flighted fastener inserted through the atleast one tile section and into the surface.